Prepared fireproof mortar



106. COMPOSlTlUNS, g COATING R PLASTIC. 1 Examiner Patented Oct. 11 1927.

UNITED STATES PATENT OFFICE.

ROBERT L. TAYLOR, OF PITTSBURGH, PENNSYLVANIA, ASSIGNOB, BY DIRECT AND MESNE ASSIGNMENTS, TO TOUPET-TAYLOB ENGINEERING COMPANY, A CORPORA- TION OF PENNSYLVANIA.

PREPARED FIBEPROOF MORTAR.

Io Drawing. Application fled January 5, 1923, Serial No. 610,903. Renewed August 13, 1927.

This invention relates to mortars, and following is an analysis of a sample of this more particularly to what I term a prepared substance fireproof mortar. Per cent One of the main objects of the invention is silica t 62 a to provide a mortar which is capab e of i a 33 75 sisting temperatures as hi h as 2200 F. and Oxide f i 2 00 which may be used for cit er interi r r x- Lime Q 1'09 terior work, or both. A f r Object is M gn si Iii: n u 04 o i a mortar which y be readily P Loss b ignitio1 1 1:00

10 need in large quantities at small cost. An-

other object is to produce a mortar the prin- Another product, which is at present a cipal ingredient of which is a substance waste product and available in large quanwhich is at present a waste product and is tities and which I use in my mortar is fer 0- available in large quantities thus rendering man anese sla This is a waste pro c 15 it possible to produce the mortar at very We need 1n the manufacture of ferro-manlow cost. ganese. The slag is drawn from the upper One of the ingredients which I use in my portion of the furnace, which is tap ed to mortar is what is known locally as red discharge this slag. Th slag is pre erably l r dog. This material results from the burndischared into a r o 20 1n of the iles of waste roduced from 1e sudden cooling of the slag as it enters mines this material Irequently taEfig He by the water causes it to becomefigmilated and g ib i neous combustion. The red dog is this granulated slag is then ischarged into the product which remains after the waste a sui a e receptacle or ta from w ich it from the mine has been burnt. This prodmay be removed at suitable times in any suit- 25 not is available in practically unlimited able or preferred manner. This slag is at quantities and, at present, mine operators present a waste product and, like the red are frequently put to considerable expense dog, possesses high bonding qualities. It

in disposing of this waste product. I have is also capable of withstanding very high discovered that this product possesses contemperatures. A typical analysis of ferrosiderable bonding qualities and is also camanganese slag suitable for use in my 1m- E pable of resisting very high temperatures. prove mor ar, 15 as follows: 80

In mining soft coal, great quantities of a waste materials are accumulated, which form Silica 2510 to 2800 piles or dumps frequently containing many Alumina 23.40 to 2420 thousands of tons of waste. This waste ma- Lime 27,04 to terial is composed largely of slate removed Magnesia 7 to 7 85 from the mine, but it also includes some coal, Manganese dioxide 6.60 to 1240 slack or cuttings of coal from the mining opserations, sulphur, and other waste materia This slag, as will be noted, has a substantial 40 These dumps frequently catch fire due to manganese content, which should not be less spontaneous combustion, and the combustible than 3%, which imparts a very desirable me- 00 substances are burned out. The substance tallic character to the mortar and materially which remains after the waste materials have increases its strength and heat resistant been burned is of a decidedly red color, and properties.

* is known in the soft coal regions as red In carrying out my invention the red dog. While there will necessarily be some do is crushed to about one-eighth of an variation in the proportions of the various inc and the ferro-manganese slag is thoringredients between samples of red dog oughly dried in a suitable manner. I then taken from different piles or localities, e mix 75 per cent of red dog and 25 per Per cent.

cent slag or 25 per cent red dog and 75 per cent slag, by volume, according to the color and grade of mortar desired. The materials are then placed into a suitable rod or ball mill and ground until the mixture has a smooth velvety feeling. This mortar in its dry state after being thoroughly pulverized is ready to use in fire-proof partitions boiler walls and exterior fire-proof construction in general.

Form liggin general and also when a hard fin1s 1 coat is desired a suitable amount, about 10 per cent by volume of h drattid pm; l101lld be added and mixed at: 1e ry material. For exterior work in general side walks and floors a suitable amount of cement. about 10 per cent by volume should be added and mixed thoroughlywi th the dr material. This mortar can be shippe to the job for the different purposes for which it is suitable. Due to red dog being a calcium material and containing a high percentage of alumina, and ferro-Inanganese slag containing lime in substantial quan- 2 tities, this mix of red dog and ferro-manganese slag is very satisfactory for interior work. This mortar, in its dry state, after being thoroughly pulverized is ready for use and can be shipped in bags to the point desired where it is mixed with water to produce a mortar of the desired consistency. If desired, though not necessarily, a small proportion of sand or ulverized slag may be added to the wet mix to obtain the desired efiect, as is the common practice, but I do not consider this at all necessary. The mortar, when mixed with water, is ready for use without addition of other material and may be used as a wall coating as well as a mortar,

producing a very hard and water-proof heat 40 resisting coating.

This mortar has been tested out and has been found to be very satisfactory as a fire resisting and water-proofing material. In addition it may be readily produced at very low cost and provides means for utilizing materials which at present are waste materials and, in many instances, constitute serious nuisances. While I prefer to mix the ingredients in substantially the proportions stated, these proportions can be varied, and cement or lime can be added to the mixture 0 re 0g an suit What I claim is:- 65

1. A mortar mix containin the residue obtained by burning coal mine slate and waste and commonly known as red dog, ferro-manganese slag, and a binder.

2. A mortar mix containin the residue obtained by burning coal mine slate and waste and commonly known as red dog, term-manganese slag, and cement.

'3. A mortar mix containin the residue obtained by burning coal mine slate and waste and commonly lmown as red dog, ferro-manganese slag, and hydraulic cement.

4. A mortar mix containin the residue obtained by burning coal mme slate and waste and commonly known as red dog, term-manganese slag, lime, and hydraulic cement.

5. A mortar mix containin the residue obtained by burning coal mine slate and waste and commonly known as red dog, 76 and ferro-manganese sla In testimony whereof afiix my signature.

ROBERT L. TAYLOR. 

